Faller bar

ABSTRACT

A faller bar unitarily formed from a single metal-strip blank by stamping and bending operations and selectively heat treated so as to possess greater hardness and wear resistance in those portions adapted for engagement with components of a gilling machine. A pair of longitudinally-extending parallel slits are provided intermediate opposite ends of the metal blank. A pinreceiving groove having an open top and open ends is formed by bending the blank at right angles along the slits. The pinreceiving groove includes a front wall and a rear wall. The rear wall has integrally formed guide portions at its opposite ends. Both rear wall and guide portions have a substantially uniform thickness, established by the material thickness of the metal blank and preselected for strength and durability to provide mating engagement between the guide portions and components of the gilling machine. The front wall has a reduced thickness relative to the back wall and establishes in combination therewith an overall predetermined thickness of the faller bar. Tab-like extension projecting integrally from each end of the front wall are manipulated to strengthen the finished bar. Removable reinforceing means can be used with the tab-like extensions to obtain a greater degree of strengthening. A plurality of longitudinally-spaced and vertically-extending notches may be formed in the confronting surfaces of the front and rear walls to provide pin-receiving slots.

United States Patet [1 1 Mohr et a1.

1 1 FALLER BAR [76] Inventors: Frederick H. Mohr, 1011 W.

Rankin Ave.; Donald R. Hoover, Rt. No. 3, both ofGastonia, NC. 28052 [22] Filed: Oct. 28, 1971 [21 1 Appl. No.: 193,342

[52] US. Cl 19/129 R [51] Int. Cl DOlg 5/14 [58] Field of Search 19/129 R [56] References Cited UNlTED STATES PATENTS 2.648.873 8/1953 Kluter 19/129 R FOREIGN PATENTS OR APPLICATIONS 4368 0/1892 Great Britain 1. 19/129 R Primary Examiner- Dorsey Newton [57] ABSTRACT A fallcr bar unitarily formed from a single metal-strip blank by stamping and bending operations and selectively heat treated so as to possess greater hardness and wear resistance in those portions adapted for en- Mar. 26, 1974 gagement with components of a gilling machine. A pair of longitudinally-extending parallel slits are provided intermediate opposite ends of the metal blank. A pin-receiving groove having an open top and open ends is formed by bending the blank at right angles along the slits. The pin-receiving groove includes a front wall and a rear wall. The rear wall has integrally formed guide portions at its opposite ends. Both rear wall and guide portions have a substantially uniform thickness, established by the material thickness of the metal blank and preselected for strength and durability to provide mating engagement between the guide portions and components of the gilling machine. The front wall has a reduced thickness relative to the back wall and establishes in combination therewith an overall predetermined thickness of the faller bar. Tab-like extension projecting integrally from each end of the front wall are manipulated to strengthen the finished bar. Removable reinforceing means can be used with the tab-like extensions to obtain a greater degree of strengthening. A plurality of longitudinally-spaced and vertically-extending notches may be formed in the confronting surfaces of the front and rear walls to provide pin-receiving slots.

7 Claims, 8 Drawing Figures Pmmmmzs 1214 3798709 INVENTORS FREDERICK H. MOHR DONALD R. HOOVER 1m, am am ATTORNEY FALLER BAR BACKGROUND OF THE INVENTION This invention relates to an improved faller bar for a gilling machine and includes the method for manufacturing such a bar. More particularly, the invention relates to a faller bar having a main body element unitarily formed from a single metal-strip blank by stamping and bending operations, which faller bar is characterized by having strength, durability and economy of fabrication to permit its use either as a reusable bar or as a disposable bar.

Illustrative of the various known faller bars relevant to the type in question are those disclosed'in US. Pat. Nos. 2,648,873; 2,648,874; 3,344,482; and 3,532,077. The known faller bars, however, are not entirely satisfactory. Some have the central portion thereof fabricated from bent up sheet-metal stock, realizing limited cost economies as a result; but require separate fabrication of the guide portions to obtain the needed hardness for overall durability of the bar and, also, to maintain the required thickness dimension for suitable operation in the gilling machine. Although such bars are reusable, they lack the cost economies necessary for disposable use.

Known faller bars of the disposable type, on the other hand, have a molded synthetic body with formed metal parts imbeded therein. The strength and durability of such bars, generally, is less than desired, and the need for both plastic molding and metal forming steps tend to reduce the overall economies experienced in the bar's fabrication, especially in view of its exclusive use as a disposable type bar.

Faller bars known to the art, therefore, either lack strength and durability necessary for efficient re-use or have a fabrication cost too high for use as a disposable bar. Such a bar that is one having strength and durability for reusable use and a fabrication cost that will enable its disposable use will provide greater flexibility in the gilling operation, thereby resulting in greater overall operating efficiencies.

SUMMARY OF THE INVENTION The present invention provides an improved faller bar, including its novel method of fabrication. Unitarily formed by stamping and bending operations from a single metal-strip blank, the faller bar has sufficient strength and durability to permit re-use of its main body portion by merely replacing the pins therein as they become worn, broken or otherwise damaged. Open ends and an open top in the bars pin-receiving groove, facilitate removal and replacement of the pins. Strength and durability are promoted by integrally forming the guide members with a rear wall portion of the bars main body, selectively heat treating parts thereof and providing the rear wall portion and guide members with a uniform thickness adapted to mate with operating parts of the gilling machine. Additional strength, durability and rigidity are realized from tablike extensions projecting integrally from the front wall portion of the bars main body. A reduced thickness in the bars front wall establishes an overall thickness dimension of the finished bar to accommodate in proper spatial relationship a preselected number of such bars operatively assembled in the gilling machine. Removable reinforcing means may be employed with the tablike extensions for still additional strength.

A pair of longitudinally-extending parallel slits, provided intermediate opposite ends of the metal blank, permit bending of the blank at right angles along the slits without bulging and folding generally associated with metal forming, thereby forming the pin-receiving groove referred to above. Vertically-extending notches, longitudinally-spaced in the confronting surfaces of the pin-receiving grooves front and rear walls form slots for receiving the pins at a predetermined spacing. The notches provide a means for initially holding the pins before a pin mounting material such as solder, epoxy or the like is applied for securely holding the pins in position. The use of a pin strip for pin holding means is thereby eliminated. Furthermore, less pin mounting material is required as a result of the pinreceiving notches, with an increase, rather than reduction, in strength and durability due to the additional support provided by the front and rear walls partially embracing the pins.

DESCRIPTION OF THE DRAWINGS The foregoing and other features and advantages of the invention will be in part evident and in part pointed out hereinafter in the following description of an illustrative embodiment thereof, which should be read in conjunction with the accompanying drawings, in which:

FIG. 1 is a front elevational view, with parts broken away, of a faller bar embodying features of the inventron;

FIG. 2 is a top plan view of the right end of the faller bar shown in FIG. 1;

FIG. 3 is a transverse, sectional view, taken substantially along lines 33 of FIG. 1;

FIG. 4 is a plan view of a reinforcing element contemplated for use in connection with the present invention;

FIG. 5 is a perspective, partially exploded view of the right end of a faller bar of the type shown in FIG. I, with the reinforcing element shown in FIG. 4 positioned therein;

FIG. 6 is a top plan view of the faller bar shown in FIG. 5;

FIG. 7 is a plan view, with part of the middle portion broken away, of a blank of the type used to fabricate the faller bar of the present invention; and

FIG. 8 is a transverse sectional view of the blank shown in FIG. 7, looking in the direction of the arrows 88 thereof.

DESCRIPTION OF THE PREFERRED EMBODIMENT The faller bar shown in FIGS. 1 and 5 includes a main body element 20 having an elongate central portion 30 with guide portions 32, 33 extending laterally therefrom. The elongate central portion 30 has a substantially U-shaped cross section forming a longitudinally extending pin-receiving groove 13 for holding therein a plurality of pin elements mounted in upright, spaced relationship. Faller bars of the type thus described are well known, therefore, additional description thereof is not deemed necessary.

The elongate central portion 30 includes an upright rear wall 31 extending the full length thereof with the guide portions 32, 33 formed integrally therewith and constituting unitary extension of the central portion, one each guide portion extending from opposite ends of the rear wall 31. The thickness of the guide portions 32, 33 and the rear wall 31 is normally uniform throughout and established by the thickness of the sheet metal stock material. The thicker the sheet metal stock the greater the strength and durability exhibited by the finished faller bar; however, two factors impose an upper limit on the thickness dimension that can be used. The faller bar guide portions 32, 33 mate with operating parts of the gilling machine in a well known manner, and, therefore, have a thickness dimension limitation imposed by the mating dimension of those operating parts. Also, the faller bars work through the gilling machine in a bank comprising a preselected number and are spaced at intervals sufficiently close to realize optimum operating efficiencies of the machine. Accordingly, the overall thickness dimension of the faller bar must remain such that the desired number thereof can be maintained in the bank and spaced at sufficient intervals.

Previous attempts to fabricate faller bars from sheet metal stock have resulted in problems caused by the strength and thickness requirements working in opposition to each other. The desired characteristics of strength and durability are obtained by increasing the thickness of the sheet metal stock, however, when the desired strength and durability is attained, the overall thickness dimension of the faller bar exceeds the limitations imposed by the facts discussed in the preceding paragraph. This problem is overcome in the present invention by selecting sheet metal stock having the thickness dimension as required and selectively heat treating parts of the faller bar so as to obtain the desired strength and durability characteristics. The desired overall thickness dimension of the faller bar is maintained by reducing in thickness a portion, preferably the front wall 35, of the elongate central portion 30 (see FIG. 8) by any suitable means such as by sanding, swaging, milling or the like. Another means for maintaining the desired overall thickness of the faller bar is to provide a plurality of longitudinally-spaced and vertically-extending notches 14, forming pin receiving slots 15, a more detailed discussion of which will follow. It is to be understood, however, that by providing the aforementioned pin-receiving slots 15, sheet metal stock having a greater thickness, and accordingly greater strength and durability, can be used without the need for reducing in thickness a portion of the elongate central portion 30.

The elongate central portion 30 of the main body element includes an upright front wall 35 extending in spaced substantially parallel relationship to the rear wall 31 and integrally connected thereto along the contiguous lower edges thereof by a bottom portion 39. Front wall 35, rear wall 31 and interconnecting bottom portion 39 define therebetween a pin receiving groove 13 having an open top 36, open ends 37, 38 and the closed bottom portion 39 heretofore mentioned.

A pair of bendable tab-like extensions 41, 42 extend laterally from and integrally with the front wall 35 at opposite ends thereof respectively. The tab-like extensions may be used to add strength and durability to the faller bar by bending them into engagement with the rear wall 31 (see FIG. 2). Additional strength and durability is realized by use of a removable reinforcing means such as the substantially flat reinforcing element 43 (see FIGS. 5 and 6). The reinforcing element 43 has a narrower end 44 with dimensions that will permit insertion thereof into the open end 37 of the pinreceiving groove 13. The opposite end 45 of the reinforcing element 43 is wider and abuts against abutting shoulder 58 formed by a plurality of shoulder like bends 52. The reinforcing element 43 may be pressfitted into position, wherein it further strengthens the bar at the point most susceptible to stress when in operation. It is to be understood that a reinforcing element 43 will be used in both ends of the pin-receiving groove 13 in the manner just described.

A blank 11 is illustrated in FIG. 7, from which the faller bar is formed. The central portion of the blank 11, forming the elongate central portion 30 of the main body element 20, includes that portion between points A and B in FIG. 7. The outer panels 32A, 33A of blank 11 form the guide portions 32, 33, respectively. A pair of angular notches 16, 17 located adjacent the opposite ends of the central portion of the blank 11 extend up wardly and inwardly toward the center of the blank 11. A pair of longitudinally extending parallel slits 12, 12' are provided in the central portion of the blank 11 and enable the bottom part thereof to be folded upwardly in parallel spaced relationship with the upper part, forming, thereby, the rear wall 31 having upper edge 64 and the front wall 35 having upper edge 64, respec tively. The purpose for the slits 12, 12' is to permit folding of the sheet metal material without the bulging and other deforming that would ordinarily result from such folding operation. A plurality of longitudinally-spaced and vertically-extending notches 14 are formed in the blank 11 intermediate the angular notches 16, 17 by any suitable means, such as stamping, cutting or the like. The distance between the notches 14 corresponds to the pins per inch desired in the finished faller bar, and after the central portion of the blank ii is folded up, forming the pin-receiving groove 13, the notches id in the confronting surfaces of the front and rear walls 35, 31 form a plurality of pin-receiving slots l5. As can be seen in FIG. 6, the pin-reciving slots 15 permit the use ofa thicker sheet metal stock than would otherwise be possible by partially embracing the upright pins 60. Furthermore, the pins 60 are held in place with geater security and less bonding material due also to the confronting surfaces of the front and rear walls partially embracing the upright pins 60.

Fabrication of the faller bar includes a combination of bending operations on the blank 11 by any suitable means such as, for example, a bending die. The order in which these operations are performed or the combination in which two or more might be performed is not significant to the practice of this invention; therefore, the following description of the bending operation is to be interpreted only as one possible arrangement thereof,

The central portion of the blank 11 is formed into the longitudinally-extending, pin-receiving groove 13 by folding the lower half thereof toward the upper half along the parallel slits 12, 12'. The longitudinallyextending parallel slits 12, 12' permit formation of the pin-receiving groove 13 with its inner walls substantially planar throughout their length. The ends of the pin-receiving groove 13 are open, thereby simplifying fabrication of the bar itself as well as reducing the difficulty normally associated with insertion and removal of the pin elements 60 therein.

The panels 32A, 33A are provided with a plurality of angular shoulder like bends 52 forming vertically disposed conductor slots 56, 57 therein. The conductor slots 56, 57 have abutting shoulders 58, 59, respectively, which shoulders are perpendicular to and facing the opposite open ends of the pin-receiving groove 13. The conductor slots 56, 57 maintain alignment of the faller bar during vertical movement thereof by working with followers (not shown) comprising part of the gilling machinery.

The faller bars opposite ends are twisted about the bars longitudinal axis to form vertically inclined bends 50, 51, thereby forming the outer inclined tongue portion 54, 55. Operating parts of the gilling machine work with the inclined tongue portion 54, 55 driving the faller bar horizontally therethrough.

Pins 60 are mounted in upstanding parallel relationship (see FIG. 1) by any suitable method. Two methods, however, have been found most satisfactory. The first contemplates positioning the pins initially in the pin-receiving groove 13, holding them therein in proper alignment and spacing and adding bonding material to secure the pins in place. Normally, a jig, referred to as a pin strip, is used to initially space and hold the pins in proper position in the pin-receiving groove 13. The pin-receiving slots avoid the need for a pin strip inasmuch as the pins are held thereby in proper spacing and position, reducing the steps normally required in pre-mounting the pins in pin strips, reducing also the cost of the finished bar. The pinreceiving slots 15 enable the front and rear walls 35, 31 to partially embrace the upright pin element 60, holding them until a binding material (not shown) such as solder or epoxy resin is added to secure the pins in the faller bars central portion. Removal of the pins 60 is accomplished very easily by applying heat until the bonding material has become soft. A pointed instrument of suitable dimension is inserted into the pinreceiving groove 13 through the open end thereof and run therethrough to remove the old pins and prepare the groove for replacement of a new assembly of pins therein. This method of mounting the upright pin elements 60 in the elongate central portion of the faller bar is preferable in those instances where the faller bar is intended for reuse.

The second means of mounting the pins 60, which is preferred in faller bars intended for disposable use, comprises placement of the pins initially into the pinreceiving slots 15, whereby the pins are frictionally held in proper alignment and spacing. The front wall is forcibly crimped against the pins to inexpensively and securely hold them in position. The tab-like extensions 41 formed by notches 16, 17 may be crimped against the rear wall 31 (see FIG. 2), thereby adding additional strength to the faller bar in the area between the guide portions 32, 33 and the elongate central portion 30, which area is subject to the greatest degree of stress during operation of the bar. For additional security, a binding material may be added but usually is not necessary.

Faller bars with pins mounted by either of the previously described methods canbe used, however, as reusable bars or as disposable bars, depending upon the re pinning facilities available to the user and the system best suited to his needs.

While the preceding description has disclosed specific embodiments of this invention in its preferred form, it is to be understood that various changes in detail and arrangement may be made without departing from the spirit and scope of the invention, the scope of the invention being defined in the claims.

What is claimed is:

1. A faller bar for gilling machines or the like, comprising:

a. an upright rear wall piece;

b. generally upright guide pieces integral with the ends of said rear wall piece, said guide pieces being of greater hardness than said rear wall piece;

c. an upright front wall piece spaced from and parallel to said rear wall piece;

d. a horizontal bottom piece integral with the lower edges of said rear and front wall pieces, and extending the length thereof, whereby said bottom, rear wall and front wall pieces form a pin-receiving groove;

e. end closing means associated with said rear wall piece and the ends of said front wall piece for closing the ends of said groove;

f. a plurality of parallel pins positioned within and extending upwardly from said groove;

g. said rear and front walls having in the faces thereof adjacent said pin-receiving groove a plurality of parallel, vertically positioned, pin-receiving notches, the notches in said rear wall being positioned opposite the notches in said front wall to form slots, said pins being positioned within said slots.

2. The faller bar of claim 1, wherein said end closing means includes reinforcing elements positioned between the ends of said front wall and said rear wall.

3. The faller bar of claim 1, wherein said front wall is of a lesser thickness than said rear wall.

4. A metal blank formable into the body element of a faller bar, said blank being comprised of a plurality of co-planar portions, said portions comprising a. a first rectangular portion having parallel sides joined by parallel ends, said first rectangular portion forming the rear wall of said faller bar;

b. a second generally rectangular portion having first and second parallel sides, said first side being coextensive with one of said sides of said first portion, said second portion being the bottom wall of said faller bar;

c. a third planar portion having first and second parallel sides, said first side of said third portion being coextensive with said second side of said second portion, the second side of said third portion being longer than the first side thereof, said third portion forming the front wall of said faller bar; and

d. Fourth and fifth planar portions, each being formed integrally with opposite ends of said first portion and extending beyond the ends thereof, said fourth and fifth portions being adaptable for formation into guide pieces in said faller bar.

5. The blank of claim 4 having a pair of parallel grooves in one surface therof, said grooves being coextensive with said first and second parallel sides of said second generally rectangular portion and serving to aid in the shaping of said blank into a faller bar.

6. The blank of claim 4, wherein a plurality of parallel pin-receiving notches extend transversely across said first, second and third planar portions.

7. The blank of claim 4, wherein said third portion is of a lesser thickness than said first portion. 

1. A faller bar for gilling machines or the like, comprising: a. an upright rear wall piece; b. generally upright guide pieces integral with the ends of said rear wall piece, said guide pieces being of greater hardness than said rear wall piece; c. an upright front wall piece spaced from and parallel to said rear wall piece; d. a horizontal bottom piece integral with the lower edges of said rear and front wall pieces, and extending the length thereof, whereby said bottom, rear wall and front wall pieces form a pin-receiving groove; e. end closing means associated with said rear wall piece and the ends of said front wall piece for closing the ends of said groove; f. a plurality of parallel pins positioned within and extending upwardly from said groove; g. said rear and front walls having in the faces thereof adjacent said pin-receiving groove a plurality of parallel, vertically positioned, pin-receiving notches, the Notches in said rear wall being positioned opposite the notches in said front wall to form slots, said pins being positioned within said slots.
 2. The faller bar of claim 1, wherein said end closing means includes reinforcing elements positioned between the ends of said front wall and said rear wall.
 3. The faller bar of claim 1, wherein said front wall is of a lesser thickness than said rear wall.
 4. A metal blank formable into the body element of a faller bar, said blank being comprised of a plurality of co-planar portions, said portions comprising a. a first rectangular portion having parallel sides joined by parallel ends, said first rectangular portion forming the rear wall of said faller bar; b. a second generally rectangular portion having first and second parallel sides, said first side being coextensive with one of said sides of said first portion, said second portion being the bottom wall of said faller bar; c. a third planar portion having first and second parallel sides, said first side of said third portion being coextensive with said second side of said second portion, the second side of said third portion being longer than the first side thereof, said third portion forming the front wall of said faller bar; and d. Fourth and fifth planar portions, each being formed integrally with opposite ends of said first portion and extending beyond the ends thereof, said fourth and fifth portions being adaptable for formation into guide pieces in said faller bar.
 5. The blank of claim 4 having a pair of parallel grooves in one surface therof, said grooves being coextensive with said first and second parallel sides of said second generally rectangular portion and serving to aid in the shaping of said blank into a faller bar.
 6. The blank of claim 4, wherein a plurality of parallel pin-receiving notches extend transversely across said first, second and third planar portions.
 7. The blank of claim 4, wherein said third portion is of a lesser thickness than said first portion. 